EP3061561B1 - Procédé de fabrication d'un composant et composant correspondant - Google Patents

Procédé de fabrication d'un composant et composant correspondant Download PDF

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Publication number
EP3061561B1
EP3061561B1 EP16152887.2A EP16152887A EP3061561B1 EP 3061561 B1 EP3061561 B1 EP 3061561B1 EP 16152887 A EP16152887 A EP 16152887A EP 3061561 B1 EP3061561 B1 EP 3061561B1
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EP
European Patent Office
Prior art keywords
producing
component
component according
blank
flange
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Active
Application number
EP16152887.2A
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German (de)
English (en)
Other versions
EP3061561A1 (fr
Inventor
Dagobert Göpfert
Alexander Gindorf
Marcus Klemm
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
MTU Aero Engines AG
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MTU Aero Engines AG
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by MTU Aero Engines AG filed Critical MTU Aero Engines AG
Publication of EP3061561A1 publication Critical patent/EP3061561A1/fr
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Publication of EP3061561B1 publication Critical patent/EP3061561B1/fr
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/34—Laser welding for purposes other than joining
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2101/00—Articles made by soldering, welding or cutting
    • B23K2101/001—Turbines
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00—Materials to be soldered, welded or cut
    • B23K2103/18—Dissimilar materials
    • B23K2103/26—Alloys of Nickel and Cobalt and Chromium
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2230/00—Manufacture
    • F05D2230/10—Manufacture by removing material
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2230/00—Manufacture
    • F05D2230/10—Manufacture by removing material
    • F05D2230/11—Manufacture by removing material by electrochemical methods
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2230/00—Manufacture
    • F05D2230/10—Manufacture by removing material
    • F05D2230/13—Manufacture by removing material using lasers
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2230/00—Manufacture
    • F05D2230/20—Manufacture essentially without removing material

Definitions

  • Certain gas turbine components such as casings, have radially outwardly directed flanges at their axial ends. Since the housing must have a certain strength while at the same time being as light as possible so that, for example, no rotating parts such as rotor blades can penetrate the housing wall, these components are preferably forged.
  • the housing wall also frequently has functional elements such as hooks, eyelets, reinforcing ribs and/or reinforcements for boroscope and cooling air eyes. Some such functional elements cannot easily be reproduced by forging. For this reason, sufficient material is formed during forging at the points at which the functional elements are arranged on the later finished housing. This means that the functional elements have to be milled out of the forged blank.
  • the excess material required for the functional element is formed over the entire circumference of the housing.
  • the functional elements are only arranged at certain points on the circumference, so that at the points on the circumference where no functional elements are arranged, a large mass of material has to be laboriously milled down to the thickness of the housing wall.
  • a more cost-effective machining process, such as turning, is not available, since the housing wall with the functional elements is usually not symmetrical in these areas.
  • the forged blank has the radial expansion of the flange over the entire axial length.
  • the radial extent of the finished housing at the height of the flange is 30 mm, for example.
  • the thickness of the housing wall can be only 4 mm, for example. This means that up to 26 mm of material would have to be removed over almost the entire axial length of the housing. This is tedious, expensive and therefore not economical.
  • the flanges are also formed during forging, but the oversize on the axial height of the housing wall is only e.g 20 mm left. In this case, the overhanging 10 mm of the flanges form undercuts in the forging or casting mold. So that these flanges can also be formed during forging, more than two dies are then necessary in order to be able to remove the blank from the mold. This has the disadvantage that the manufacturing costs for the blank increase.
  • the present invention is therefore based on the object of presenting a method for producing a component, namely a housing of a gas turbine, which is faster, cheaper and more precise.
  • the object is solved by the features of claim 1.
  • the object is also achieved by the features of claim 14.
  • the forged blank essentially has the shape of a truncated cone.
  • This has the advantage that the forging blank has been greatly simplified.
  • the forged blank has no undercuts. The costs for the dies are greatly reduced. Only two dies are required for such a simple blank geometry without undercuts.
  • the lateral surface of the truncated cone has the strength of a forged component, so that the wall thicknesses there can be thinner than with a cast material. This has in turn result in the finished component being lighter.
  • a flange area is formed on at least one axial end of the truncated cone, which extends the truncated cone parallel to its axis of symmetry. Both ends of the truncated cone preferably have flange regions running parallel to the axis of symmetry.
  • the additional material is applied with an allowance of at most 1 mm, in particular at most 0.5 mm, compared to the final contour of the finished component. This has the advantage that there is little effort involved in later removing excess material. It also saves the cost of the additional material.
  • the additional material is applied in layers in step b.). This offers the possibility of applying one layer with a certain composition and applying another layer with a different composition.
  • step b. material is only applied to the at least one point which protrudes from the original surface of the forged blank in the final contour.
  • material is only applied to the at least one point which protrudes from the original surface of the forged blank in the final contour.
  • the blank has a simplified geometry.
  • the outer contour of the forged blank is optimized to such an extent that, on the one hand, the forging is close to the final shape, so that later only little material has to be removed and, on the other hand, material only has to be applied in a few places.
  • the places to be applied with material are, in particular, areas that are difficult or impossible to produce by forging or that only protrude at certain points over the surface of the forged part.
  • the method is optimized in such a way that minimal material has to be removed from the forging blank and minimal new material has to be applied. This allows the manufacturing costs and material costs to be reduced enormously.
  • step b. the material is applied in such a way that a functional element of the component is created.
  • Functional elements are, for example, add-on parts on the component such as hooks, eyelets, etc.
  • flange extensions and/or reinforcements for boroscopes and/or cooling air eyes can also be reinforcing struts or reinforcing ribs which, for example, connect a turbine center frame to the hub of the gas turbine.
  • the functional element is a flange extension running perpendicularly to the axis of symmetry and radially outwards at one axial end of the flange area.
  • Flanges consisting of a forged flange area and an applied flange extension offer the greatest potential for simplification with this process.
  • the material of the additional material is different from the material of the forged blank.
  • the forged blank can be made from Ti-64 and the functional areas can be made from Ti-6242.
  • Another material pairing can be IN625 for the raw part and IN718 or DA718 for the additionally applied material.
  • each load zone on the component is provided with an appropriate material that meets the required strength.
  • material is removed only at at least one functional point.
  • Functional points in particular functional surfaces, are, for example, openings, eyes, bores and/or bearing surfaces of the flanges. These functional points must comply with a specified dimensional accuracy, so that the component is compatible with other components during installation. Other surfaces do not need to be reworked.
  • material applied in step b.) is not removed.
  • the removal takes place mechanically and/or electrochemically in step c.).
  • the mechanical removal takes place by turning and/or milling, whereby in particular the smallest possible part should be milled, since the Milling is a very time-consuming and costly manufacturing step.
  • the electrochemical removal (ECM - electro chemical manufacturing) takes place in a bath of electrolyte. The stock is connected positively as the anode and the tool is connected negatively as the cathode. A current flows between the two, causing the material of the blank to dissolve in the electrolyte.
  • a contact surface is worked into the forged blank between steps a.) and b.).
  • an abutment surface is turned inside the flange portion of the forged blank. This contact surface can be precisely manufactured and serves as a reference surface for further processing, since the forged blank can be clamped and centered over it.
  • the forged blank is heat-treated with additional material between steps b.) and c.). This serves to eliminate mechanical stress in the material.
  • the heat treatment can be done globally via an oven. However, the heat treatment can also be carried out locally by means of a laser or an induction coil.
  • the Figures 1 and 2 show a rotationally symmetrical forged blank 2, which has a truncated cone 4, a first flange area 6, which is on the first axial (in the figure 1 left) end 8 of the truncated cone 4 is formed, and has a second flange portion 10 which in the figure 1 on the second axial (in the figure 1 right) end 12 of the truncated cone 4 is formed.
  • the two flange areas 6 and 10 run parallel to the axis of symmetry A, with the first inner diameter D 1 of the first flange area 6 being larger than the second inner diameter D 2 of the second flange area 10.
  • the blank 2 can, for example, be forged from a cylindrical tube with an inside diameter that is slightly smaller than the second inside diameter D 2 .
  • An outer die has the outer shape of the blank 2 and an inner die has the inner shape of the blank 2 .
  • the outer die could in the figure 1 be located on the right and the inner die could be located on the left in the figure.
  • the inner die moves with high pressure along the axis of symmetry A and presses the glowing mass of the tube into the outer die, so that the shape of the forged blank 2 is created.
  • the inner surfaces of the flange areas 6 and 10 can be machined to size, so that the dedicated contact surfaces 14 and 16 are created.
  • the blank 2 is clamped and centered on at least one of these contact surfaces 14 and 16 .
  • FIG 3 is a section along the line III-III in figure 2 pictured.
  • the section of the blank 2 is only shown as a double-dotted line.
  • the representation in figure 3 essentially an enlargement of the dash-dotted detail figure 1 , where the magnification is rotated 90° counter-clockwise relative to the section.
  • a section through a finished housing 30 is shown as solid lines. This representation shows at which points on the forged blank 2 new material has to be applied or material of the forged blank 2 can be removed.
  • a first flange extension 32 running radially outwards is integrally formed on the axial end of the first flange region 6 (shown here below).
  • a second flange extension 34 running radially outwards is integrally formed on the axial end of the second flange region 10 (now shown here at the top). These two flange extensions 32 and 34 project beyond the original outer surface 18 of the forged blank 2 . These flange extensions 32 and 34 run rotationally symmetrically over the entire circumference of the housing 30.
  • the housing 30 can have a boroscope eye 36 or the like, around which a boroscope reinforcement 38 can be arranged. A portion of this boroscope reinforcement 38 projects beyond the original outer surface 18 of the forged blank 2 .
  • Such boroscope eyes 36 with reinforcements 38 are arranged, for example, only every 60° over the circumference, so that there are a total of six boroscope eyes distributed evenly over the circumference. An irregular distribution over the circumference is also conceivable.
  • the housing 30 has a rotationally symmetrical reinforcing strut 40 on the inside, which projects beyond the original inner surface 20 of the forged blank 2 .
  • the flange extensions 32 and 34, the borescope reinforcement 38 and the reinforcing strut 40 can be referred to generically as functional elements of the housing 30.
  • a first flange 46 is formed from the first flange area 6 and the first flange extension 32 .
  • a second flange 48 is formed from the second flange area 10 and the second flange extension 34 .
  • these functional elements are generatively applied to the surface 18 or 20 of the forged blank 2 by means of laser deposition welding.
  • the functional elements can be applied in layers. This offers the possibility of one layer having one alloy composition and another layer having a different alloy composition.
  • the blank has a first alloy composition such as Ti-64 or IN625 and at least one functional element has a second alloy composition such as Ti-6242, IN718 and/or DA718. It is thus conceivable that a first functional element has a second alloy composition and that another functional element has a third alloy composition.
  • the individual functional element can also have the alloy composition of the blank 2 .
  • references elevations are any elevations formed on the outer surface 18 or on the inner surface 20 of the blank 2, which have a specific position, specific dimensions and a specific position in relation to another component.
  • the reference elevations can be bone-shaped.
  • surface 18 or 20 pre-treatment may be required. Preferably only an allowance of material of maximum 1 mm is applied. The allowance can also be as little as 0.5 mm.
  • step b. material only needs to be applied at the points at which the subsequent functional elements are arranged, since in this exemplary embodiment all functional elements project beyond the original surfaces 18 and 20 of the blank 2 .
  • the housing 30 can be heat-treated locally (for example inductively and/or with the aid of a laser) or globally (via an oven) in order to reduce the internal stress in the material. Temperatures from 500° to 650°C are suitable. This heat treatment is also referred to as stress relieving.
  • the forged blank is machined or electrochemically reworked so that material is removed.
  • the functional surface includes the first surface 42 of the first flange 46 running perpendicularly to the axis of symmetry
  • a figure 3 is arranged at the bottom and runs horizontally, and the perpendicular to the axis of symmetry
  • a running second surface 44 of the second flange 48, which in the figure 3 is located at the top and runs horizontally.
  • both flange surfaces 42 and 44 are parallel to each other. This ensures that the components to be attached to the flanges 46 and 48 are correctly aligned with the axis of symmetry.
  • Additional functional surfaces are conceivable on the outer surface of the housing 30 . So can the one in the figure 3 have a further functional surface 50 in the upper region of the boroscope reinforcement 38 .
  • Areas provided with reference numeral 52 are referred to as areas to be removed. This means that the corresponding surfaces of the housing 30 are inside the forged blank 2 .
  • these areas 52 of the housing 30 would not have to be removed for cost reasons.
  • the weight plays a minor role in stationary gas turbines. The removal of these areas 52 serves in particular to reduce the weight of the housing 30 .
  • the weight contributes to the efficiency, so that the effort is required to remove the material accordingly.
  • the casing 30 may be a turbine center frame or a low pressure turbine casing.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Plasma & Fusion (AREA)
  • Forging (AREA)
  • General Engineering & Computer Science (AREA)

Claims (14)

  1. Procédé de fabrication d'un composant, à savoir d'un carter (30) d'une turbine à gaz, comportant les étapes suivantes :
    a. la fourniture d'une ébauche de forge (2) à symétrie de révolution,
    b. l'application de matière supplémentaire en au moins un matériau sur la surface de l'ébauche (18, 20) à au moins un point,
    c. l'enlèvement de matière jusqu'au contour final du composant (30) fini, caractérisé en ce qu'à l'étape b.)
    - l'application s'effectue par soudage par dépôt au laser à l'aide de fil et
    - la matière est appliquée de telle sorte qu'un élément fonctionnel du composant est formé, en particulier des renforts pour boroscopes.
  2. Procédé de fabrication d'un composant selon la revendication 1, caractérisé en ce que l'ébauche de forge (2) présente sensiblement la forme d'un tronc de cône (4).
  3. Procédé de fabrication d'un composant selon la revendication 2, caractérisé en ce qu'une zone de bride (6, 10) est formée au niveau d'au moins une extrémité (8, 12) du tronc de cône (4), laquelle prolonge le tronc de cône (4) parallèlement à son axe de symétrie (A).
  4. Procédé de fabrication d'un composant selon au moins l'une quelconque des revendications précédentes, caractérisé en ce qu'à l'étape b.) la matière supplémentaire est appliquée avec une surépaisseur d'au plus 1 mm, en particulier d'au plus 0,5 mm, par rapport au contour final.
  5. Procédé de fabrication d'un composant selon au moins l'une quelconque des revendications précédentes, caractérisé en ce qu'à l'étape b.) la matière supplémentaire est appliquée en couches.
  6. Procédé de fabrication d'un composant selon au moins l'une quelconque des revendications précédentes, caractérisé en ce qu'à l'étape b.) de la matière n'est appliquée qu'au niveau de l'au moins un point, lequel fait saillie dans le contour final depuis la surface (18, 20) d'origine de l'ébauche de forge (2).
  7. Procédé de fabrication d'un composant selon au moins l'une quelconque des revendications précédentes, caractérisé en ce qu'à l'étape b.) la matière est appliquée de telle sorte qu'un élément fonctionnel (32, 34, 36, 38, 40) du composant (30) est formé.
  8. Procédé de fabrication d'un composant selon la revendication 7, caractérisé en ce que l'élément fonctionnel est un élargissement de bride (32, 34) s'étendant radialement vers l'extérieur et perpendiculairement à l'axe de symétrie (A) au niveau d'une extrémité axiale de la zone de bride (6, 10).
  9. Procédé de fabrication d'un composant selon au moins l'une quelconque des revendications précédentes, caractérisé en ce qu'à l'étape b.) le matériau de la matière supplémentaire est différent du matériau de l'ébauche de forge (2).
  10. Procédé de fabrication d'un composant selon au moins l'une quelconque des revendications précédentes, caractérisé en ce qu'à l'étape c.) de la matière est enlevée uniquement au niveau d'au moins un point fonctionnel (42, 44, 50).
  11. Procédé de fabrication d'un composant selon au moins l'une quelconque des revendications précédentes, caractérisé en ce qu'à l'étape c.) l'enlèvement s'effectue mécaniquement et/ou chimiquement.
  12. Procédé de fabrication d'un composant selon au moins l'une quelconque des revendications précédentes, caractérisé en ce qu'entre les étapes a.) et b.) une surface d'appui (14, 16) est intégrée dans l'ébauche de forge (2).
  13. Procédé de fabrication d'un composant selon au moins l'une quelconque des revendications précédentes, caractérisé en ce qu'entre les étapes b.) et c.) l'ébauche de forge (2) est traitée thermiquement avec de la matière supplémentaire.
  14. Composant fabriqué selon un procédé selon au moins l'une quelconque des revendications précédentes, caractérisé en ce que ledit composant (30) est un carter central de turbine et/ou un carter pour une turbine basse pression.
EP16152887.2A 2015-02-24 2016-01-27 Procédé de fabrication d'un composant et composant correspondant Active EP3061561B1 (fr)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
DE102015203234.5A DE102015203234B4 (de) 2015-02-24 2015-02-24 Verfahren zur Herstellung eines Bauteils, nämlich einens Gehäuses einer Gasturbine und das entsprechende Bauteil

Publications (2)

Publication Number Publication Date
EP3061561A1 EP3061561A1 (fr) 2016-08-31
EP3061561B1 true EP3061561B1 (fr) 2022-11-16

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Application Number Title Priority Date Filing Date
EP16152887.2A Active EP3061561B1 (fr) 2015-02-24 2016-01-27 Procédé de fabrication d'un composant et composant correspondant

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US (1) US20160245120A1 (fr)
EP (1) EP3061561B1 (fr)
DE (1) DE102015203234B4 (fr)

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GB2553531B (en) * 2016-09-07 2019-02-06 Rolls Royce Plc A method of attaching a projection to a thin walled component
EP3519681A4 (fr) * 2016-09-29 2020-12-02 GKN Aerospace Newington LLC Procédé de fabrication de pièces cylindriques
CN112658698A (zh) * 2020-12-07 2021-04-16 北京星航机电装备有限公司 一种薄壁壳体零件的简易生产线

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Also Published As

Publication number Publication date
DE102015203234B4 (de) 2018-04-26
EP3061561A1 (fr) 2016-08-31
US20160245120A1 (en) 2016-08-25
DE102015203234A1 (de) 2016-08-25

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